Electrical connector

ABSTRACT

An electrical connector includes both a terminal having an annular recess therearound intermediate portions of the terminal of larger cross section and a block of nonconductive material having an aperture therein for receiving the terminal. A flexible wall forms a portion of the terminal block and this wall extends along and defines at least a portion of the length of the block&#39;&#39;s terminal receiving aperture. A locating tab, secured to the flexible wall, enters the annular recess of the terminal to position it within the receiving aperture. A locking device is attached to the block to prevent the free flexing of the flexible wall when the tab has positioned the terminal within the aperture.

[54} ELECTRICAL CONNECTOR 7 Claims, 8 Drawing Figs.

[52] US. Cl 339/59, 339/91, 339/217, 339/176 [51] Int. Cl H01! 13/54,

HOlr 9/l6 [50] Field of Search 339/59 M,

64,74, 191 A, 191 M, 191, 192, 195, 195 A, 195 M, 195 8,217,2178, 75M,62, 63,91 R, 176M UNITED STATES PATENTS 3,101,229 8/1963 Yopp 339/593,430,135 2/1969 511216161111. 339/59M U 39 I 4/ Z i /7 3/ United StatesPatent 1111 3, 1,

[72] inventor ThomasM.Cairns 3,477,061 11/1969 Stephenson 339/59MDell011,MiCh. 3,487,355 12 1969 Cairns 339/176 1 1 pp 8071733 FORElGNPATENTS 5253 1:413: 933,045 7/1963 GreatBritain 339 192 [73] AssignFordMmrCompany 956,993 4 1964 01661131116111 339/64M Dearborn, Mich.Primary ExaminerMarvin A. Champion Assistant Examiner-Lawrence J. StaabAttorneys-John R. Faulkner and William E. Johnson ABSTRACT: Anelectrical connector includes both a terminal having an annular recesstherearound intermediate portions of the terminal of larger crosssection and a block of nonconductive material having an aperture thereinfor receiving the terminal. A flexible wall forms a portion of theterminal block and this wall extends along and defines at least aportion of the length of the blocks terminal receiving aperture. Alocating tab, secured to the flexible wall, enters the annular recess ofthe terminal to position it within the receiving aperture. A lockingdevice is attached to the block to prevent the free flexing of theflexible wall when the tab has positioned the terminal within theaperture.

PATENTEDAUB24I97I 3,601. 760

SHEET 1 [IF 2 7 39 55 2 39 22 0 0 Z7 E 33 O W) 25 39 O O A;

IE1; is 35 4/ 35 EGA- 55 23 4 54 56 52 FL /0 IN VENTOR.

THOMAS M. CAIRNS Iii; 5

ELECTRICAL CONNECTOR BACKGROUND OF THE INVENTION This inventionconstitutes an improvement of the type of 5 electrical connectorsdisclosed and claimed in my copending U.S. Pat. application, Ser. No.692,822, filed Dec. 22, 1967, now U.S. Pat. No. 3,487,355. Thisapplication also discloses and claims an electrical connector which mayutilize terminals such as disclosed and claimed in my copending U.S.Pat. application, Ser. No. 719,479, filed Apr. 8, 1968, now U.S. Pat.No. 3,482,207. Briefly the improvement for the electrical connector isfound in the fact that individual ones of a plurality of terminals maybe inserted into terminal block and temporarily located therein whileother individual ones of the plurality of terminals may be inserted intothe block. The temporary positioning of the terminals maintains themwithin the block even though the block is tipped or roughly handled.Once the desired number of terminals have been inserted into theterminal block and temporarily located therein, a single member is theninserted into the block to lock all of the terminals securelytherewithin. The locking member cannot be installed fully into positionunless each terminal is either properly installed or obviously notinstalled. This removes operator judgment.

SUMMARY OF THE INVENTION This invention is directed to an electricalconnector and, more particularly, the invention is directed to theconstruction of an electrical connector in which a terminal may beinserted into and temporarily secured within a terminal block, theterminal subsequently being fully secured within the block for usethereof.

The electrical connector of this invention is formed by inserting aterminal of an electrically conductive material into a terminalreceiving aperture fonned in a terminal block of nonconductive material.The terminal is formed so as to have an annular recess therearoundintermediate portions of the terminal of larger cross section. Theimprovement in the connector comprises a flexible wall secured to theterminal block. The flexible wall defines at least a portion of thelength of the terminal-receiving aperture. A locating tab, associatedwith the terminal-receiving aperture, enters the annular recess of theterminal to position the terminal properly within the receivingaperture. A locking device is thereafter attached to the terminal blockto prevent the free flexing of the flexible wall when the locating tabhas positioned a terminal properly within the receiving aperture.

With such a terminal block construction, a first terminal may beinitially inserted into one of the apertures formed in the terminalblock. Upon insertion of the initial terminal, the locating tabassociated with the particular terminal-receiving aperture will enterthe recess of the terminal to position the terminal within the aperture.The flexible wall provides sufficient flexing of the terminal-receivingaperture so that the larger portions of an individual terminal may bemoved past the locating tab associated with that aperture. Once thelocating tab has entered the annular recess of the individual terminal,the lateral movement of the terminal within the aperture is restricted.A locking device is then attached to the terminal block to prevent thefree flexing of the flexible wall whereby the confinement of theelectric terminal by the locating tab within the terminal-receivingaperture is continued until the locking device is removed.

In greater detail, the locating tab is formed as a portion of theflexible wall. In still greater detail, the electrical connector has atleast a pair of terminal-receiving apertures defined in the terminalblock. The flexible walls of the pair of terminalreceiving apertures arein juxtaposition with a space therebetween. In this construction, thelocking device is formed as a bar and is inserted between the pair ofopposed flexible walls. In further detail, the electrical connector hasa plurality of pairs of associated terminals receiving apertures alignedin such a manner that the space between the jux taposed flexible wallsof each pair of apertures forms a single, continuous passageway. In thisconstruction a single locking bar is inserted into the space between theflexible walls to lock securely all of the terminals which have beeninserted within the terminal block.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is an isometric view of a maleor plug connector assembled with a female or cap connector, bothconnectors being formed in accordance with the principles and teachingsof a first embodiment of this invention.

FIG. 2 is a view, partly in cross section, along the length of theassembled electrical connectors shown in FIG. I, the view showing theinterior structure in greater detail.

FIG. 3 is a view, in enlarged cross section, across the width of theelectrical connectors of FIG. 1, the view both showing terminalspositioned within the connectors and showing still further details ofthe structure.

FIG. 4 is an end elevation view of the male connector.

FIG. 5 is a view, partly in cross section, along the length of a secondembodiment of assembled electrical connectors constructed in accordancewith the teachings of this invention.

FIG. 6 is a view, in cross section, across the width of the electricalconnectors of FIG. 5.

FIG. 7 is an end elevation view of the male or plug connector shown inFIGS. 5 and 6.

FIG. 8 is an enlarged view of the locking member utilized in theconnector construction shown in FIGS. 5 and 6.

DESCRIPTION OF THE PREFERRED EMBODIMENT Construction for FirstEmbodiment My U.S. Pat. application, Ser. No. 692,882, now U.S. Pat. No.3,487,355, teaches an electrical connector construction in whichelectric terminals having annular recesses are locked to a terminalblock by use of a locking bar which enters an annular recess of eachterminal after the terminal has been positioned in a terminal-receivingaperture of the block. My prior connector construction provides alocating shoulder for initial positioning of each terminal within itsaperture so that the locking bar can be directed into the recessedportion of the terminal to secure the terminal to the block. Theconnector disclosed in this application constitutes an improvement of myprior connector. The new connector includes structure for initiallyretaining the inserted terminal in the aperture of the terminal blockprior to being locked therein. Once initially retained, the terminalcannot be dislodged from the aperture by tipping or shaking the terminalblock. Also, after once being retained, the terminal may be latersecurely locked within the aperture by the insertion of a locking bar.

A first embodiment of the electrical connector of this invention isshown in FIGS. 1 to 4 of the drawings. While the invention is shown anddescribed in conjunction with an electrical connector having both aplurality of terminals and a plurality of terminal-receiving apertures,it is to be understood that the principles and teachings of thisinvention may be employed with a terminal block having only a singleaperture therein.

In FIG. I, a female or cap electrical connector is generally designatedby the numeral 10, and a male or plug electrical connector is generallydesignated by the numeral II. Each of these connectors is formed inaccordance with the principles and teachings of this invention. Withreference to FIG. 3, it is seen that the plug connector 11 supportstherewithin a plurality of female electric terminals 12. On the otherhand, the cap connector 10 supports therewithin a plurality of maleelectric terminals 13. The terminal may be formed in accordance with theprinciples and teachings of my copending application, Ser. No. 719,479,now U.S. Pat. No. 3,482,207. The only major requirement for theterminals is that each terminal has associated therewith an annularrecess intermediate portions of the terminal of larger diameter or crosssection. More particularly, with respect to terminal 12, a recess 14 isprovided therein intermediate portions of the terminal of larger crosssection. Similarly, the terminal 13 is also provided with a recess 16which is located intermediate areas of the terminal of larger crosssection.

The cap connector and plug connector 1 l are formed so as to have a verysimilar structure. The one major exception in formation of the twoconnectors is that terminal-receiving apertures 17 of the plug connectorextend along the entire length of the terminals 12 located therewithin,best seen in FIG. 3. On the other hand, the terminal-receiving apertures18 of the cap connector 10 extend only along a portion of the length ofthe terminal 13 received therewithin.

Now with reference to FIGS. 1, 2 and 3, the construction of the plugconnector 11 will be described in detail. The plug or male connector hasexterior sidewalls 21 and 22, as well as a top wall and a bottom wall,respectively designated 23 and 24. A vertical center wall 26 is providedbetween the sidewalls. A pair of partition walls 27 and 28 are providedbetween the top wall and the bottom wall to divide the connector intothe plurality of mentioned terminal-receiving apertures 17.

The center wall 26 of the connector 11, as best seen in FIGS. 2 and 3,is bifurcated near one end thereof to form two angularly disposed walls31 and 32. In FIG. 2, only the wall 31 is shown. However, it is shown inthat figure that there are three of the angularly disposed walls 31depending from the center wall. Each of the angularly disposed walls isassociated with a different terminal-receiving aperture 17. This may beunderstood by reference to one of the single terminal-receivingapertures shown in FIG. 3. Each of the plurality of angularly disposedwalls 31 and 32 terminate at the beginning of a flexible wall 33associated therewith. As seen in plan view in FIG. 2, a lateral space 34is provided between each flexible wall and its associated sidewall orpartition wall which were previously designated 23, 24, 27 and 28. Thefree end 36 of each of theflexible walls 33 terminates at a positionbeyond the end of the terminal 12 received within associatedterminalreceiving aperture 17 of the connector 11.

As best seen in FIG. 3, associated pairs of the flexible walls 33 are injuxtaposition to one another with a space 37 therebetween. Each of theflexible walls 33 defines a portion of the length of one of theterminal-receiving apertures 17 of the connector 11. Each of theflexible walls 33 has associated therewith a locating tab 39. Thelocating tab is seen in FIG. 3 but not in FIG. 2. As shown in FIG. 3,the locating tabs 39 project inwardly from their associated flexiblewall into an associated terminal-receiving aperture 17. FIG. 4 shows howthe locating tabs 39 project into the associated annular recesses 14 ofthe terminals 12. The locating tabs are made to conform to the generalconfiguration of the annular recess of the terminals. Thus, when thelocating tab is positioned within a recess of a terminal, the lateralmovement of the terminal within the terminal-receiving aperture issubstantially restricted. However, the float normal to the terminal axisis not restricted.

Now with references to FIGS. 3 and 4, a locking bar 41 is shown insertedin the space 37 between the juxtaposed flexible walls 33. In particular,this bar occupies the space between the juxtaposed locating tabs 39provided on the flexible walls. The locking bar engages locatingsurfaces 42 and 43 respectively on the partition walls 27 and 28, seeFIG. 2. The extremities of the locking bar engage, respectively,locating surfaces 44 and 46 formed on the top wall 23 and bottom wall 24of the connector 11. Since the locating surfaces 42 and 43 are opposedto the locating surfaces 44 and 46, the locking bar is held therebetweenwhen the bar is in its fully inserted position. The locking bar also haspositioning projections 47 (FIG. 2) thereon which selectively engageeither the surface 42 or the surface 43 to stabilize the bar in itsinserted position. As best seen in FIG. 4, the locking bar is insertedby being moved laterally along the length of the space 37 between eachpair of associated flexible walls 33.

The female or cap connector 10, which houses the terminals 13, isconstructed in a manner similar to the construction of the plugconnector 11. As seen in FIG. 1, the cap connector 10 has the frontportion 51 thereof formed so as to receive internally the front portionof the plug connector. The upper surface 52 of the front portion 51 hasa recess 53 therein which terminates at a crossbar 54. The crossbarcooperates with a detent 56 formed on the upper surface 23 of the plugconnector. When the two connectors are assembled, the crossbar anddetent cooperate to lock the two connectors together into a single unit.When the two connectors are locked together, the terminals 12 and 13 arebrought into electrical connection with one another.

Operation of the First Embodiment With reference to FIGS. 3 and 4 of thedrawings, a terminal 12 may be inserted into a terminal aperture 17 ofthe connector 11 by the following steps. During the insertion of theterminal into its aperture, the locking bar 41 is not positioned in thespace 37 between the juxtaposed pairs of flexible walls 33. Thus, as theterminal is inserted into its aperture, the front of the terminal willengage the locating tab 39 formed on the flexible wall. The front of theterminal will act on the locating tab to flex the wall 33 into the freespace 37 between it and the opposed wall. The flexing of the wallpermits the larger front portion of the terminal to move past thelocating tab until such time as the annular recess 14 is aligned withthe tab. At this time the tab enters the recess as the flexible wallreturns to its normal position with respect to the remainder of theterminalreciving aperture.

The terminal, now inserted into its aperture, is properly located in theconnector. The connector may be shaken or otherwise moved or tippedwithout dislodging the inserted terminal. However, since the locking baris not inserted, one may still remove the terminal from the aperture.The removal is effected by applying a sufficient force on the lead ofthe terminal whereby the locating tab once again will be caused to acton the flexible wall to cam the wall into the free space.

Once the desired number of tenninals have been inserted into theconnector 11, the locking bar 41 is inserted into the space 37 betweenthe associated pairs of flexible walls 33. The locking bar moves downthe full length of the space between each of the three spaced pairs ofterminal-receiving apertures and is positioned in its proper position byengagement of the positioning projections 47 with the partition wall 27.When the locking bar 41 is in its fully inserted position, the flexiblewalls and, in particular, the locating tabs 39, thereof, are not free toflex from their normal position. In other words, any force applied alongthe axis of the terminal 12 does not cause a camming of the flexiblewall into the space 37 permitting easy extraction of the terminalbecause movement of the wall is restricted. Thus, once the locking bar41 has been inserted into the connector 11, the individual terminals aresecurely held within the terminal block. However, when the locking baris removed, it is a simple matter to remove any terminals from theconnector by applying a proper force thereto.

As an alternate construction, the locating tab 39 may be positioned onthe wall of the termnal-receiving aperture opposite the flexible wall33. This particular construction would require the tipping or canting ofthe terminal during insertion thereof to apply a force against theflexible wall to move the wall out of position.

Construction for Second Embodiment In the construction of the electricalconnectors, in accordance with the second embodiment of this invention,the major change is in the design of the locking bar inserted betweenthe opposed flexible walls of the connector. Since many similar detailsof construction are utilized in the two embodiments, all similar detailswill be identified by the same names and reference numerals as utilizedin the description of the first embodiment structure. Also, since boththe plug and cap connectors are similar in construction, descriptionthis section will be undertaken only of the plug connector.

In the second embodiment structure, a locking bar 61, shown in isometricview in FIG. 8, is utilized to enter the space 37 between the flexiblewalls 33. The locking bar is provided with a notch 62 and a detent 63for purposes which will be described in greater detail hereafter.

The connector 11, as shown in FIG. 7, is modified with respect to theconnector shown in FIG. 4 in that the top wall 23 and the bottom wall 24have recesses 64 and 66 respectively therein. These recesses are for thepurpose of receiving for movement therealong the lateral side edges ofthe locking bar 61. Also, a portion of the partition wall 28 of theconnector is modified so as to extend into the space 37 provided betweenthe opposed flexible walls 33. The extending portion 67 of the partitionwall 28 is received within the notch 62 of the locking bar to guide thebar during its insertion into the connector.

The bottom wall 24 of the connector, as best seen in FIG. 5, has at theleading portion thereof an opening 68. The opening is terminated by aportion 69 of the bottom wall 24 which extends across the whole bottomthereof. The detent 63 of the locking bar 61 is received behind thisportion of the bottom wall to position the bar in its fully insertedposition within the connector.

Operation of the Second Embodiment The operation of the secondembodiment structure is similar to the first embodiment structure in themanner in which the terminals are inserted within their respectiveterminal-receiving apertures. As an individual terminal is inserted, theleading portion thereof engages the locating tab 39 on the flexible wall33 and causes the wall to be cammed into the space 37 between thejuxtaposed walls. After the terminal has been moved along the length ofits aperture, the locating tab 39 enters the recess 14 to position andlocate the terminal within its aperture. After all of the terminals 12are inserted within their associated apertures, the locking bar isinserted from right to left as viewed in FIG. 6. In order to accomplishthis insertion operation, the notch 62 of the locking bar 61 is alignedwith and positioned on the extending portion 67 of the partition wall28. The locking bar is then moved to the left as viewed in FIG. 6 untilthe detent 63 slides over the portion 69 of the bottom wall 24. When thelocking bar is in its fully inserted position, the terminals are heldsecurely within the connector 11.

I claim:

1. In an electrical connector which includes at least a plurality ofpairs of cylindrical, electrical terminals, each terminal having anannular recess therein about the circumference thereof intermediateportions of the terminal of larger diameter, and a block ofnonconductive material having a plurality of pairs of apertures forreceiving the terminals therein, the improvement comprising:

a first flexible wall associated with one of each pair of apertures andsecured to the block of nonconductive material and defining at least aportion of the length of the one terminal-receiving aperture of eachpair of apertures;

a second flexible wall associated with the other of each pair ofapertures and secured to the block of nonconductive material anddefining at least a portion of the length of the otherterminal-receiving aperture of each pair of apertures, said firstflexible wall and said second flexible wall of each pair of aperturesbeing in juxtaposition with one another with a space therebetween andthe pairs of terminal-receiving apertures being aligned in a side byside relationship with said space between each pair of apertures beingaligned;

locating means secured to each of said flexible walls and extending intoits associated terminal-receiving aperture, said locating means forentering the annular recess of the terminal inserted into the associatedaperture for positiqning the terminal properly within that aperture andlocking means comprising a single member msertable within said alignedspaces between said flexible walls of said pairs of apertures forpreventing the free flexing of said flexible walls when terminals havebeen located within their associated terminal-receiving apertures.

2. The improved electrical connector as defined in claim 1 wherein saidlocating means on each of said flexible walls is a projection whichextends into its associated terminal-receiving cavity; and wherein saidblock of nonconductive material is provided with means for aligning saidlocking means in said space between said pairs of associated aperturesin such a position that the locking means is adjacent said inwardlydirected projections formed on said flexible walls.

3. The improved electrical connector as defined in claim 2 wherein saidaligning means on the nonconductive block consist of both surfacesformed between adjacent pairs of associated terminal-receiving aperturesand surfaces at both extremities of the associated pairs of apertures,said surfaces at said extremities and said surfaces between each pair ofapertures being positioned on opposite sides of said locking means whensaid locking means is inserted in its position between said flexiblewalls; and wherein said locking means is a bar of nonconductive materialwhich is insertable into said space between said associated pairs ofapertures by being moved laterally across said space from one extremityof said associated pairs of apertures to said other extremity of saidassociated pairs of apertures.

4. The improved electrical connector as defined in claim 3 furthercomprising: projecting portions on said locking bar for engagement withat least one of said surfaces between adjacent pairs of associatedterminal-receiving apertures for stabilizing said locking bar in aprescribed attitude within the connector after being inserted therein.

5. The improved electrical connector as defined in claim 2 wherein saidlocking bar comprises a piece of nonconductive material insertablebetween said flexible walls by movement inwardly along the length of thespace between said pairs of associated walls.

6. The improved electrical connector as defined in claim 5 wherein oneof the sidewalls of the block of nonconductive material is provided withan aperture; and wherein said locking bar is provided with a detentwhich enters said aperture when said locking bar is in a fully insertedposition whereby said locking bar is held in a fixed position relativeto said flexible walls after insertion.

7. The improved electrical connector as defined in claim 6 wherein oneof the walls between an associated pair of terminal-receiving aperturesextends into the space between said flexible walls to provide a guide;and wherein said locking bar has a notch along the length thereof, saidnotch and said projecting wall cooperating to properly position saidlocking member during its movement into and along said space betweensaid associated pairs of flexible walls.

1. In an electrical connector which includes at least a plurality ofpairs of cylindrical, electrical terminals, each terminal having anannular recess therein about the circumference thereof intermediateportions of the terminal of larger diameter, and a block ofnonconductive material having a plurality of pairs of apertures forreceiving the terminals therein, the improvement comprising: a firstflexible wall associated with one of each pair of apertures and securedto the block of nonconductive material and defining at least a portionof the length of the one terminal-receiving aperture of each pair ofapertures; a second flexible wall associated with the other of each pairof apertures and secured to the block of nonconductive material anddefining at least a portion of the length of the otherterminal-receiving aperture of each pair of apertures, said firstflexible wall and said second flexible wall of each pair of aperturesbeing in juxtaposition with one another with a space therebetween andthe pairs of terminal-receiving apertures being aligned in a side byside relationship with said space between each pair of apertures beingaligned; locating means secured to each of said flexible walls andextending into its associated terminal-receiving aperture, said locatingmeans for entering the annular recess of the terminal inserted into theassociated aperture for positioning the terminal properly within thataperture; and locking means comprising a single member insertable withinsaid aligned spaces between said flexible walls of said pairs ofapertures for preventing the free flexing of said flexible walls whenterminals have been located within their associated terminal-receivingapertures.
 2. The improved electrical connector as defined in claim 1wherein said locating means on each of said flexible walls is aprojection which extends into its associated terminal-receiving cavity;and wherein said block of nonconductive material is provided with meansfor aligning said locking means in said space between said pairs ofassociated apertures in such a position that the locking means isadjacent said inwardly directed projections formed on said flexiblewalls.
 3. The improved electrical connector as defined in claim 2wherein said aligning means on the nonconductive block consist of bothsurfaces formed between adjacent pairs of associated terminal-receivingapertures and surfaces at both extremities of the associated pairs ofapertures, said surfaces at said extremities and said surfaces betweeneach pair of apertures being positioned on opposite sides of saidlocking means when said locking means is inserted in its positionbetween said flexible walls; and wherein said locking means is a bar ofnonconductive material which is insertable into said space between saidassociated pairs of apertures by being moved laterally across said spacefrom one extremity of said associated pairs of apertures to said otherextremity of said associated pairs of apertures.
 4. The improvedelectrical connector as defined in claim 3 further comprising:projecting portions on said locking bar for engagement with at least oneof said surfaces between adjacent pairs of associated terminal-receivingapertures for stabilizing said locking bar in a prescribed attitudewithin the connectoR after being inserted therein.
 5. The improvedelectrical connector as defined in claim 2 wherein said locking barcomprises a piece of nonconductive material insertable between saidflexible walls by movement inwardly along the length of the spacebetween said pairs of associated walls.
 6. The improved electricalconnector as defined in claim 5 wherein one of the sidewalls of theblock of nonconductive material is provided with an aperture; andwherein said locking bar is provided with a detent which enters saidaperture when said locking bar is in a fully inserted position wherebysaid locking bar is held in a fixed position relative to said flexiblewalls after insertion.
 7. The improved electrical connector as definedin claim 6 wherein one of the walls between an associated pair ofterminal-receiving apertures extends into the space between saidflexible walls to provide a guide; and wherein said locking bar has anotch along the length thereof, said notch and said projecting wallcooperating to properly position said locking member during its movementinto and along said space between said associated pairs of flexiblewalls.